Transfer Assembly: Reassembly

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

INSTALL TRANSFER DRIVE CLUTCH HUB
1. Using SST and a press, press in the drive clutch hub.
  SST 09513-36040
  
  Fig 1: Pressing In Drive Clutch Hub Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE CLUTCH SLEEVE
1. Apply gear oil to the connecting areas of the clutch sleeve and clutch hub.
2. Install the drive clutch sleeve onto the rear output shaft.
  NOTE: Make sure that the clutch sleeve is installed facing the correct direction.
  
  Fig 2: Identifying Drive Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 3 No. 1 synchromesh shifting keys and 2 No. 1 synchromesh shifting key springs.
  NOTE: Install the key springs so that their end gaps are not aligned.
  
  Fig 3: Installing Synchromesh Shifting Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER SYNCHRONIZER RING SET
1. Install the outer synchronizer ring onto the rear output shaft.
  NOTE: Align the slots of the outer synchronizer ring with the shifting keys.
  
  Fig 4: Identifying Outer Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the center synchronizer ring onto the rear output shaft.
  
  Fig 5: Identifying Center Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the inner synchronizer rings onto the rear output shaft.
  NOTE: Align the slots of the outer synchronizer ring with those of the inner rings.
  
  Fig 6: Identifying Inner Synchronizer Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
1. Install a new drive sprocket bearing.
  
  Fig 7: Identifying Drive Sprocket Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the drive sprocket.
  
  Fig 8: Identifying Drive Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Align the cutouts in the drive sprocket with the protrusions on the center synchronizer ring.
INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING
1. Using SST and a press, press in a new bearing.
  NOTE: Make sure the bearing is installed in the correct direction.
  
  SST 09316-60011 (09316-00011)
  
  Fig 9: Pressing In Bearing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
1. Using a feeler gauge, measure the drive sprocket thrust clearance.
  Standard clearance: 0.10 to 0.26 mm (0.00394 to 0.0102 in.)
  
  Maximum clearance: 0.26 mm (0.0102 in.)
  
  If the clearance is greater than the maximum, replace the drive sprocket sub-assembly.
  
  Fig 10: Measuring Drive Sprocket Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSFER CLUTCH HUB

Using SST and a press, press in the clutch hub.
SST 09316-60011 (09316-00011)

Fig 11: Pressing In Clutch Hub Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring that allows for minimum axial play and install it to the shaft.

Snap ring thickness

SNAP RING THICKNESS

Mark	Thickness
B	2.12 to 2.17 mm (0.0835 to 0.0854 in.
C	2.17 to 2.22 mm (0.0854 to 0.0874 in.
D	2.22 to 2.27 mm (0.0874 to 0.0894 in.
E	2.27 to 2.32 mm (0.0894 to 0.0913 in.
F	2.32 to 2.37 mm (0.0913 to 0.0933 in.
G	2.37 to 2.42 mm (0.0933 to 0.0953 in.
H	2.42 to 2.47 mm (0.0953 to 0.0974 in.
J	2.47 to 2.52 mm (0.0974 to 0.0992 in.
K	2.52 to 2.57 mm (0.0992 to 0.101 in.)

Fig 12: Identifying Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a snap ring expander, install the snap ring.
NOTE: Make sure that the snap ring is firmly installed to the groove.

INSTALL TRANSFER HIGH AND LOW CLUTCH SLEEVE
1. Install the high and low clutch sleeve onto the clutch hub.
  NOTE: Make sure that the high and low clutch sleeve is installed facing the correct direction.
  
  Fig 13: Identifying High And Low Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER SYNCHROMESH SHIFTING KEY SPRING
1. Install the synchromesh shifting key and synchromesh shifting key spring as shown in the illustration.
  
  Fig 14: Identifying Synchromesh Shifting Key And Synchromesh Shifting Key Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, install the snap ring.
  
  Fig 15: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure that the snap ring is firmly installed to the groove.
INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER
1. Install the washer, low planetary gear bearing and output shaft spacer to the output shaft.
  
  Fig 16: Identifying Washer, Low Planetary Gear Bearing And Output Shaft Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, install the snap ring.
  NOTE: Make sure that the snap ring is firmly installed to the groove.
  
  Fig 17: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE FRONT OIL SEAL
1. Using SST and a hammer, tap in a new oil seal until its surface is 1 to 1.5 mm (0.0394 to 0.0591 in.) from the front case upper surface.
  SST 09950-60020 (09951-00720), 09950-70010 (09951-07100)
  
  NOTE: Be careful not to damage the front case.
  
  Fig 18: Tapping In Oil Seal Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the lip of the oil seal with MP grease.
INSTALL TRANSFER DRIVEN SPROCKET BEARING
1. Install the bearing to the front case in the direction shown in the illustration.
  
  Fig 19: Identifying Bearing Install Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure the bearing is installed in the correct direction.
2. Using a screwdriver, install the snap ring.
  
  Fig 20: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER LOW PLANETARY RING GEAR
1. Install the ring gear to the transfer front case.
  
  Fig 21: Identifying Low Planetary Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure to install the ring gear in the correct direction.
2. Using a screwdriver, install the snap ring.
  
  Fig 22: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure that the snap ring is firmly installed to the groove.
INSTALL TRANSFER INPUT SHAFT PLUG
1. Using SST and a hammer, tap in a new input shaft plug.
  SST 09316-60011 (09316-00011)
  
  NOTE: Be careful not to damage or deform the input shaft plug when tapping it.
  
  Fig 23: Tapping In Input Shaft Plug Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY
1. Install the low planetary gear bearing and low planetary gear to the input shaft.
  NOTE: Make sure the low planetary gear bearing is installed in the correct direction.
  
  Fig 24: Identifying Low Planetary Gear Bearing And Low Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the low planetary gear spline piece.
  NOTE: Make sure that the end gap of the snap ring is not aligned with the cutout of the planetary carrier.
  
  Fig 25: Installing Low Planetary Gear Spline Piece
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSFER INPUT SHAFT BEARING

Install the input shaft bearing and low planetary gear bearing to the input shaft.
NOTE:
- Make sure the input shaft bearing are installed in the correct direction.
- Make sure that the temper color side of the low planetary gear bearing faces downward.
Fig 26: Identifying Input Shaft Bearing And Low Planetary Gear Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST and a press, press in a new bearing.
SST 09513-36040

NOTE: After press-fitting the bearing to the input shaft, check that the bearing moves smoothly.

Fig 27: Pressing In Bearing Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring that allows for minimum axial play and install it to the shaft.

Snap ring thickness

SNAP RING THICKNESS

Mark	Thickness
C	2.13 to 2.18 mm (0.0839 to 0.0858 in.)
D	2.18 to 2.23 mm (0.0858 to 0.0878 in.)
E	2.23 to 2.28 mm (0.0878 to 0.0898 in.)
F	2.28 to 2.33 mm (0.0898 to 0.0917 in.)
G	2.33 to 2.38 mm (0.0918 to 0.0937 in.)
H	2.38 to 2.43 mm (0.0937 to 0.0957 in.)
J	2.43 to 2.48 mm (0.0957 to 0.0976 in.)

Fig 28: Identifying Snap Ring

Using a snap ring expander, install the snap ring.
NOTE: Make sure that the snap ring is firmly installed to the groove.

INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING
1. Install a new seal ring to the input shaft.
  
  Fig 29: Identifying No. 1 Transfer Input Shaft Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OIL SEAL RING
1. Install a new seal ring to the input shaft.
  
  Fig 30: Identifying Transfer Oil Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT ASSEMBLY
1. Install the snap ring to the front case.
  
  Fig 31: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While expanding the snap ring, install the input shaft to the front case.
3. Apply adhesive to the threads of the 2 plugs.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
4. Install the 2 plugs.
  Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
  
  Fig 33: Identifying Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE MAGNET
INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY
1. Install the oil separator with the 3 bolts.
  Torque: 17 N*m (178 kgf*cm, 13 ft.*lbf)
  
  Fig 34: Identifying Oil Separator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE REAR OIL SEAL
1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear case upper surface.
  SST 09950-60020 (09951 -00710), 09950-70010 (09951-07100)
  
  NOTE: Be careful not to damage the rear case.
  
  Fig 35: Installing Oil Seal Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the lip of the oil seal with MP grease.
INSTALL SIDE GEAR SHAFT HOLDER BEARING
1. Install the side gear shaft holder bearing to the rear case.
2. Using a screwdriver, install the snap ring.
  
  Fig 36: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR OUTPUT SHAFT
1. Install the snap ring to the rear case.
2. Mount the rear case in a vise.
  NOTE: Place aluminum plates on the vise to prevent damage to the rear case.
3. Install the output washer to the rear output shaft.
  
  Fig 37: Identifying Rear Output Shaft Output Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the rear output shaft, front drive chain and driven sprocket.
  NOTE: Do not drop the clutch sleeve or shifting key.
  
  Fig 38: Identifying Rear Output Shaft, Front Drive Chain And Driven Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a snap ring expander, install the snap ring.
  NOTE: Make sure that the snap ring is firmly installed to the groove.
  
  Fig 39: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY
1. Install a new O-ring to the shift actuator.
  
  Fig 40: Identifying Shift Actuator O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set the No. 1 gear shift fork and No. 2 gear shift fork to the rear case. Then install the shift actuator to the rear case with the 3 bolts.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Fig 41: Identifying Shift Actuator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSFER GEAR SHIFT FORK
1. Install the No. 1 gear shift fork to the shift actuator with the bolt.
  Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
  
  Fig 42: Identifying No. 1 Gear Shift Fork Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 TRANSFER GEAR SHIFT FORK
1. Install the No. 2 gear shift fork to the shift actuator with the bolt.
  Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
  
  Fig 43: Identifying No. 2 Gear Shift Fork Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver and hammer, tap the 3 shift fork shaft snap rings into the shift fork shaft.
  
  Fig 44: Identifying Shift Fork Shaft Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR TRANSFER CASE
1. Install the output shaft front needle roller bearing and No. 3 synchronizer ring outer to the output shaft.
  
  Fig 45: Identifying Output Shaft Front Needle Roller Bearing And No. 3 Synchronizer Ring Outer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply seal packing to the rear case as shown in the illustration.
  Seal packing:
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  
  Fig 46: Identifying Seal Packing To Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If the removed rear case will be reused: After removing the rear case, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the rear case's contact surface, 2) clean off any remaining old FIPG from the rear case's contact surface, and 3) reapply seal packing to the rear case.
3. Install the rear case with the 14 bolts.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  Fig 47: Identifying Rear Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Tighten the bolts of the rear case within 10 minutes of applying the seal packing. The seal packing will dry very quickly.
INSTALL TRANSFER CASE PLUG
1. Apply adhesive to the threads of the plug.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
2. Install the plug.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 48: Identifying Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSFER CASE PLUG
1. Install the pin and compression spring to the front case.
2. Apply adhesive to the threads of the plug.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
3. Install the plug.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
4. Apply adhesive to the threads of the plug.
INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Install the companion flange sub-assembly onto the drive sprocket sub-assembly.
2. Using SST to hold the companion flange, install a new companion flange lock nut.
  SST 09330-00021
  
  Torque: 127 N*m (1299 kgf*cm, 94 ft.*lbf)
  
  Fig 50: Installing Companion Flange Lock Nut Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a chisel and hammer, stake the companion flange lock nut.
Fig 51: Identifying Companion Flange Lock Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Install the companion flange onto the output shaft.
2. Using SST to hold the companion flange, install a new companion flange lock nut.
  SST 09330-00021
  
  Torque: 127 N*m (1299 kgf*cm, 94 ft.*lbf)
  
  Fig 52: Installing Companion Flange Lock Nut Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a chisel and hammer, stake the companion flange lock nut.
  
  Fig 53: Identifying Companion Flange Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OIL PUMP PLATE OIL SEAL
1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump plate upper surface.
  SST 09950-60010 (09951-00680), 09950-70010 (09951-07100)
  
  NOTE: Be careful not to damage the oil pump plate.
  
  Fig 54: Identifying Transfer Oil Pump Plate Oil Seal Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE PLUG
1. Install the relief valve seat, ball and compression ring to the oil pump plate.
2. Apply adhesive to the threads of the plug.
  Adhesive:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
3. Using a 10 mm hexagon wrench, install the plug.
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
INSTALL TRANSFER CASE STRAIGHT PIN
1. Install the straight pin to the input shaft.
INSTALL TRANSFER OIL PUMP PLATE
1. Apply transfer oil to a new O-ring, drive rotor and driven rotor.
2. Install the O-ring, drive rotor and driven rotor to the oil pump plate.
  
  Fig 57: Identifying O-Ring, Drive Rotor And Driven Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil pump plate with the 4 bolts.
  Torque: 11 N*m (117 kgf*cm, 9 ft.*lbf)
  
  Fig 58: Identifying Oil Pump Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002